Research on the underlying mechanism behind abrasive flow machining on micro-slit structures and simulation of viscoelastic media

doi:10.1007/s40436-022-00395-0

Advances in Manufacturing ›› 2022, Vol. 10 ›› Issue (3): 382-396.doi: 10.1007/s40436-022-00395-0

• ARTICLES • 上一篇

Research on the underlying mechanism behind abrasive flow machining on micro-slit structures and simulation of viscoelastic media

Bao-Cai Zhang¹, Shi-Fei Chen¹, Nasim Khiabani¹, Yu Qiao¹, Xin-Chang Wang¹

School of Mechanical Engineering, Shanghai Jiao Tong University, Shanghai 200240, People's Republic of China

收稿日期:2021-11-10 修回日期:2022-01-08 发布日期:2022-09-08
通讯作者: Xin-Chang Wang E-mail:wangxinchang@sjtu.edu.cn
基金资助:
This study was sponsored by the National Natural Science Foundation of China (Grant No. 52175423), KeyArea Research and Development Program of Guangdong Province (Guangdong Science and Technology Department) (Grant No. 2020B010185001), Huohua Project (Grant No. 20-163-00-TS-009- 159-01), and Shanghai Municipal Human Resources and Social Security Bureau-Pujiang Program (Grant No. 2019PJD021).

Research on the underlying mechanism behind abrasive flow machining on micro-slit structures and simulation of viscoelastic media

Bao-Cai Zhang¹, Shi-Fei Chen¹, Nasim Khiabani¹, Yu Qiao¹, Xin-Chang Wang¹

School of Mechanical Engineering, Shanghai Jiao Tong University, Shanghai 200240, People's Republic of China

Received:2021-11-10 Revised:2022-01-08 Published:2022-09-08
Supported by:
This study was sponsored by the National Natural Science Foundation of China (Grant No. 52175423), KeyArea Research and Development Program of Guangdong Province (Guangdong Science and Technology Department) (Grant No. 2020B010185001), Huohua Project (Grant No. 20-163-00-TS-009- 159-01), and Shanghai Municipal Human Resources and Social Security Bureau-Pujiang Program (Grant No. 2019PJD021).

摘要/Abstract

摘要： In this study, the machining mechanism of abrasive flow machining (AFM) microstructures was analyzed in depth according to the transmission morphology and rheological behaviors of the abrasive media. The transmission morphology demonstrated the excellent combination of the polymer melt with abrasive grains at the interface, indicating that the polymer melt, combined with the uniform distribution of the polymer chains, could exert a harmonious axial force on the abrasive grains. Based on the rheological behavior analysis of the abrasive media, for example, the stress relaxation and moduli of storage and loss, a machining mechanism model was established incorporating the effect of microplastic deformation and continuous viscous flow, which was further verified by the grooves along the flow direction. In addition, the PhanThien-Tanner (PTT) model combined with a wall slipping model was employed to simulate the machining process for the first time here. The value of the simulated pressure (1.3 MPa) was similar to the measured pressure (1.45 MPa), as well as the simulated volumetric rate (0.011 4 mL/s) to the measured volumetric rate (0.067 mL/s), which further proved the validity of the simulation results. The flow duration (21 s) derived from a velocity of 1.2 mm/s further confirmed the residual stretched state of the polymer chains, which favored the elasticity of the abrasive media on the grains. Meanwhile, the roughly uniform distribution of the shear rate at the main machining region exhibited the advantages of evenly spread storage and loss moduli, contributing to the even extension of indentation caused by the grains on the target surface, which agreed with the mechanism model and machined surface morphology.

The full text can be downloaded at https://link.springer.com/article/10.1007/s40436-022-00395-0

关键词: Abrasive flow machining (AFM), Microstructure, Machining mechanism, Phan-ThienTanner (PTT) model, Experimental verification

Abstract: In this study, the machining mechanism of abrasive flow machining (AFM) microstructures was analyzed in depth according to the transmission morphology and rheological behaviors of the abrasive media. The transmission morphology demonstrated the excellent combination of the polymer melt with abrasive grains at the interface, indicating that the polymer melt, combined with the uniform distribution of the polymer chains, could exert a harmonious axial force on the abrasive grains. Based on the rheological behavior analysis of the abrasive media, for example, the stress relaxation and moduli of storage and loss, a machining mechanism model was established incorporating the effect of microplastic deformation and continuous viscous flow, which was further verified by the grooves along the flow direction. In addition, the PhanThien-Tanner (PTT) model combined with a wall slipping model was employed to simulate the machining process for the first time here. The value of the simulated pressure (1.3 MPa) was similar to the measured pressure (1.45 MPa), as well as the simulated volumetric rate (0.011 4 mL/s) to the measured volumetric rate (0.067 mL/s), which further proved the validity of the simulation results. The flow duration (21 s) derived from a velocity of 1.2 mm/s further confirmed the residual stretched state of the polymer chains, which favored the elasticity of the abrasive media on the grains. Meanwhile, the roughly uniform distribution of the shear rate at the main machining region exhibited the advantages of evenly spread storage and loss moduli, contributing to the even extension of indentation caused by the grains on the target surface, which agreed with the mechanism model and machined surface morphology.

The full text can be downloaded at https://link.springer.com/article/10.1007/s40436-022-00395-0

Key words: Abrasive flow machining (AFM), Microstructure, Machining mechanism, Phan-ThienTanner (PTT) model, Experimental verification

Bao-Cai Zhang, Shi-Fei Chen, Nasim Khiabani, Yu Qiao, Xin-Chang Wang. Research on the underlying mechanism behind abrasive flow machining on micro-slit structures and simulation of viscoelastic media[J]. Advances in Manufacturing, 2022, 10(3): 382-396.

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Research on the underlying mechanism behind abrasive flow machining on micro-slit structures and simulation of viscoelastic media

Research on the underlying mechanism behind abrasive flow machining on micro-slit structures and simulation of viscoelastic media

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